Milltronics ACCUMASS BW500 Instruction Manual
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Milltronics ACCUMASS BW500 Instruction Manual

Belt scale integrator
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ACCUMASS BW500
Instruction Manual PL-565
January 2001
33455650
Rev. 1.2

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Summary of Contents for Milltronics ACCUMASS BW500

  • Page 1 ACCUMASS BW500 Instruction Manual PL-565 January 2001 33455650 Rev. 1.2...
  • Page 2 We welcome all suggestions for improvement. Technical data subject to change. MILLTRONICS®is a registered trademark of Siemens Milltronics Process Instruments Inc. Contact SMPI Technical Publications at the following address: Technical Publications Siemens Milltronics Process Instruments Inc.

  • Page 3: Table Of Contents

    Table of Contents About this….........................7 About This Manual ...................7 About the Accumass BW500 ................8 Accumass BW500 features: ..............8 Specifications......................9 Installation .........................13 Dimensions ....................13 Optional Plug-ins....................14 ® SmartLinx Module ..................14 mA I/O board ...................15 Layout ......................16 Interconnection ....................17 System Diagram..................17 Scale – One Load Cell ................18 Scale –...
  • Page 4 Setpoint Controller – Rate Control ............96 Setpoint Controller – Load Control............96 Setpoint Controller – Master/Slave Control..........97 Setpoint Controller – Rate and Load Control ..........98 Setup and Tuning...................98 Proportional Control (Gain), P ..............98 Integral Control (Automatic Reset), I............99 Page 4 Accumass BW500 PL-565...
  • Page 5 Modbus Register Map ................123 Modbus Register Map (cont’d) ..............125 Modems....................133 Error Handling ..................135 Troubleshooting......................137 Generally ....................137 Specifically.....................137 Error Codes....................138 Appendices......................139 Memory Backup ...................139 Software Updates ..................139 Calibration Criteria ..................139 Zero: ......................139 Span: .....................139 PID Systems:..................139 PL-565 Accumass BW500 Page 5...
  • Page 6 Page 6 Accumass BW500 PL-565...

  • Page 7: About This

    Appendices this manual has an alphabetical cross reference of the parameters to their numbers, a diagnostic help with the list of error messages, a maintenance reminder, and a record sheet for jotting down parameter values. PL-565 Accumass BW500 Page 7...

  • Page 8: About The Accumass Bw500

    About the Accumass BW500 Note: The ACCUMASS BW500 is to be used only in the manner outlined in this instruction manual. The ACCUMASS BW500 is a microprocessor based integrator designed for use with Milltronics, or equivalent belt scales and weigh feeders. The speed and load signals from the conveyor and scale, respectively, are processed to derive rate of material flow, and totalization.

  • Page 9: Specifications

    I/O board auxiliary 5 discrete inputs for external contacts, each programmable for either: display scrolling, totalizer 1 reset, zero, span, multispan, print, batch reset, or PID function. PL-565 Accumass BW500 Page 9...
  • Page 10 300 m (1000 ft) max Options: Speed Sensor: Mass Dynamics MD-36 / 36A / 256 or 2000A, or RBSS, or compatible Dolphin Plus: Milltronics Windows based software interface. Refer to associated product documentation ® SmartLinx Modules: protocol specific modules for interface with popular industrial communications systems.
  • Page 11 24 V dc at 50 mA, short circuit protected LVDT interface card: for interface with LVDT based scales Weight 2.6 kg (5.7 lb.) Approvals: CE*, CSA NRTL/C *EMC performance available upon request PL-565 Accumass BW500 Page 11...
  • Page 12 Page 12 Accumass BW500 PL-565...

  • Page 13: Installation

    (4 places) cable glands to maintain ingress rating. customer mounting screw 3. Non metallic enclosure does not provide grounding between connections. Use grounding type bushings and jumpers. PL-565 Accumass BW500 Page 13...

  • Page 14: Optional Plug-Ins

    SmartLinx ® Module ® The BW500 is software/hardware ready to accept the optional Milltronics SmartLinx communications module that provides an interface to one of several popular industrial communications systems. ® Your BW500 may be shipped to you without a SmartLinx module, for installation at a later date.

  • Page 15: Ma I/O Board

    • mA I/O Parameters (P200 - P220) on page 65 • mA I/O (0/4-20 mA) in the Operation section on page 91 ® SmartLinx ® route SmartLinx cable along right hand wall mA I/O board PL-565 Accumass BW500 Page 15...

  • Page 16: Layout

    Relay contact terminals are for use with equipment having no accessible live parts and wiring having insulation suitable for at least 250 V • The maximum allowable working voltage between adjacent relay contact shall be 250 V. Page 16 Accumass BW500 PL-565...

  • Page 17: Interconnection

    Milltronics Dolphin, print data, or Modbus ASCII or RTU protocol Note: Typical system capability. Not all components or their maximum quantity may be required. PL-565 Accumass BW500 Page 17...

  • Page 18: Scale - One Load Cell

    : BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' • If load cell wiring colours vary from those shown, or if extra wires are provided, consult Milltronics. Page 18 Accumass BW500 PL-565...

  • Page 19: Scale - Two Load Cell

    : BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' • If load cell wiring colours vary from those shown, or if extra wires are provided, consult Milltronics. PL-565 Accumass BW500 Page 19...

  • Page 20: Scale - Four Load Cell

    : BW500 terminal 12 to scale `red' BW500 terminal 13 to scale `blk' • If load cell wiring colours vary from those shown, or if extra wires are provided, consult Milltronics. Page 20 Accumass BW500 PL-565...

  • Page 21: Scale - Lvdt

    BW500 terminal 12 to integrator terminal block ‘+EXC’ BW500 terminal 13 to integrator terminal block ‘-EXC’ For further connection information on specific LVDT’s consult Milltronics. ♦Shields are common, but not grounded to chassis. Run cable shields through SHLD terminals and ground at BW500 only.

  • Page 22: Speed

    Input device in the form of open collector transistor or dry contact across BW500 terminals 16 / 17 will also serve as a suitable speed signal. • If a speed sensor other than the models shown is supplied, consult with Milltronics for details Page 22...

  • Page 23: Auxiliary Inputs

    Customer dry contacts, or open collector transistor output supplied as required Refer to P270 on page 67 for programming details. Auto Zero prefeed activated dry contact Refer to Auto Zero on page 47.. RS-232 Port 1 Printers Printer receive common PL-565 Accumass BW500 Page 23...

  • Page 24: Computers And Modems

    For connection to a PC compatible computer or modem, using no flow control, typical configurations are: DB-9 DB-25 Remote Totalizer supply, 30V max remote totalizer 1 supply, 240V max remote totalizer 2 mA Output 1 to customer instrumentation, isolated mA output, 750 Ω maximum load Page 24 Accumass BW500 PL-565...

  • Page 25: Relay Output

    Relay Output Relays shown in de-energized state, contacts normally open, rated 5 A at 250 V non- inductive RS-485 Port 2 Daisy Chain customer device Terminal Device customer device PL-565 Accumass BW500 Page 25...

  • Page 26: Port 3

    100 / 115 / 200 / 230V 50 / 60 Hz select voltage via switch Page 26 Accumass BW500 PL-565...

  • Page 27: Ma I/O Board

    Specifications) should be replaced every 5 years to insure memory back up during lengthy power outages. An on board capacitor provides 20 minutes of charge in order to preserve the memory while the battery is being changed. PL-565 Accumass BW500 Page 27...
  • Page 28 Page 28 Accumass BW500 PL-565...

  • Page 29: Start Up

    Press to change PID local setpoint values PID auto/manual switch Print Press to initiate calibration Press to enter PROGRAM mode Press to scroll through run displays press to reset totalizer 1 PL-565 Accumass BW500 Page 29...

  • Page 30: Program Mode

    N N N N u u u u m m m m b b b b e e e e r r r r Page 30 Accumass BW500 PL-565...

  • Page 31: Run Mode

    In order to operate the BW500 in the run mode, the unit must undergo an initial programming to set up the base operating parameters. Attempting to enter the run mode without satisfying the program requirements, forces the program routine to the first missing item. PL-565 Accumass BW500 Page 31...

  • Page 32: Initial Start Up

    / / / / m m m m m m m m i i i i i i i i n n n n n n n n 1 1 1 1 1 1 1 1 Page 32 Accumass BW500 PL-565...
  • Page 33 ..0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 If the speed input is configured for constant speed, display value reads ‘Jumpered’, press to advance. PL-565 Accumass BW500 Page 33...
  • Page 34 Parameters (P693 – P699) Page 34 Accumass BW500 PL-565...

  • Page 35: Load Cell Balancing

    Unbalanced load cells adversely affect the performance of your belt conveyor weighing system. With the conveyor stopped and locked out, lift the belt off the weighing idlers. Typical two load cell belt scale Belt travel load cell load cell test weight bar ‘B’ ‘A’ PL-565 Accumass BW500 Page 35...
  • Page 36 ..Page 36 Accumass BW500 PL-565...
  • Page 37 E E E E N N N N T T T T E E E E R R R R ..‘A’ ‘B’ ‘C’ ‘D’ test weight PL-565 Accumass BW500 Page 37...

  • Page 38: Zero Calibration

    # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # # Page 38 Accumass BW500 PL-565...

  • Page 39: Span Calibration

    ..check for proper load cell wiring. PL-565 Accumass BW500 Page 39...

  • Page 40: Run Mode

    (P019). Recalibration of the zero and span are ongoing requirements that must be performed routinely in order to maintain accurate reporting of rate and total. Refer now to the Recalibration. Page 40 Accumass BW500 PL-565...

  • Page 41: Recalibration

    ..6 6 6 6 3 3 3 3 m m m m / / / / s s s s The displayed speed (used in the rate computation) now equals the actual speed. PL-565 Accumass BW500 Page 41...

  • Page 42: Material Tests

    If the span adjust value is not acceptable, repeat the material test to verify repeatability. If the result of the second material test differs considerably, consult Milltronics or their agent. If the span adjust values are significant and repeatable, perform a manual span...
  • Page 43 5 5 5 5 6 6 6 6 6 6 6 6 ..7 7 7 7 7 7 7 7 8 8 8 8 8 8 8 8 is displayed PL-565 Accumass BW500 Page 43...

  • Page 44: Material Test

    Where parameters have been changed with a resultant impact on the calibration, they do not take effect until a recalibration is done. If significant changes have been made, an initial zero (P377) and/or initial span (P388) may be required. Page 44 Accumass BW500 PL-565...

  • Page 45: Recalibration

    Note: End of Zero Calibration. Proceed with Span Recalibration or return to Run. PL-565 Accumass BW500 Page 45...

  • Page 46: Initial Zero

    5 5 5 5 5 5 5 5 1 1 1 1 4 4 4 4 0 0 0 0 1 1 1 1 count Page 46 Accumass BW500 PL-565...

  • Page 47: Auto Zero

    ..PL-565 Accumass BW500 Page 47...
  • Page 48 Note: End of span calibration. Remove the test weight and return to run. Page 48 Accumass BW500 PL-565...

  • Page 49: Initial Span

    Note: End of span calibration. Remove the test weight and return to run. PL-565 Accumass BW500 Page 49...

  • Page 50: Direct Span

    P365, or by external contacts connected to the Auxiliary input, and programmed via P270. In order to enable multispan operation, the following must be addressed. • connection • programming • calibration • operation Page 50 Accumass BW500 PL-565...
  • Page 51 If remote span selection is desired, Auxiliary Inputs, 1 and/or 2 and/or 3, must be programmed in order to read the contact state as the span selection. Remote selection overrides keypad (or Dolphin Plus) selection. The auxiliary inputs override the key pad selection. PL-565 Accumass BW500 Page 51...
  • Page 52 Aux 1 Aux 2 Aux 3 It may be required to reset or note the totalizer value, as the process materials being conveyed change. Refer to Operation on page 89 Linearization applies concurrently to spans. Page 52 Accumass BW500 PL-565...

  • Page 53: Factoring

    5 5 5 5 ..2 2 2 2 5 5 5 5 mode if so desired Note: If multispan function is used, the test load value is stored for the current multispan only. PL-565 Accumass BW500 Page 53...

  • Page 54: Linearization

    • After the compensation has been programmed into the BW500, a material test should be run to verify the effect of linearization. • If additional compensation is required, it must be based on new material tests performed with the linearization turned off (P390 = 0). Page 54 Accumass BW500 PL-565...
  • Page 55 BW500 8.7 ♦ belt scale response -5.1 ♦ linearized BW500 response internal response 100% - 150% of span 11.1 ♦ % compensation -10.7 ♦ span (100%) Load – kg / m PL-565 Accumass BW500 Page 55...
  • Page 56 P392-02 = 0 point 2, compensation actual weight per material test totalized weight by BW500 belt scale response linearized BW500 response internal response, 100-150% of span % compensation -10.7 ♦ span (100%) Load – kg / m Page 56 Accumass BW500 PL-565...

  • Page 57: Parameter Description

    Locks out the program editor so that parameter values for P001 through P999 cannot be changed. This however does not prevent the access to the parameters for viewing. Programming is locked out if the value of P000 is other than 1954. entry: 1954 = unlocked 1954 = locked PL-565 Accumass BW500 Page 57...

  • Page 58: Start Up (P001 To P017)

    P003 Number of Load Cells Milltronics belt scales are available in models of one, two or four load cell design. Select the number of load cells corresponding to the belt scale connected. If using the optional remote LVDT conditioner card, for LVDT based scales, select the “1”...
  • Page 59 Specifies the design speed for the conveyor belt. (f=0.00) Speed units are: feet/min if the imperial system of measurement has been selected, P004 = 1 metres/s if the metric system of measurement has been selected, P004 = 2 PL-565 Accumass BW500 Page 59...
  • Page 60 If the displayed speed is not equal to the actual speed, enter the actual belt speed. (f=0.00) For speed sensor applications, the value of P015 is automatically adjusted. For constant speed (terminals 17/18 jumpered) the value of P014 is automatically adjusted. Page 60 Accumass BW500 PL-565...
  • Page 61 The run displays are scrolled either manually by pressing ALT DISP if the scroll mode is set to off, or automatically if the mode is set to on. entry: 0 = off 1 = on PL-565 Accumass BW500 Page 61...

  • Page 62: Relay/Alarm Function (P100 - P117)

    Sets the low alarm setpoint for relay selected, relays 1 to 5 (P100 - 01 to – 05). (f=20) Enter the value in % of full scale Note: Not applicable if P100 = 4, 5, 6, 7 or 8. Page 62 Accumass BW500 PL-565...
  • Page 63 This parameter allows the reversal of the operation. Normally, P118 = 2 for each relay. Reverse Operation When P118 = 3, the operation of the indexed relay is reverse from normal. Values P118 Logic Relay positive logic normally closed negative logic normally open PL-565 Accumass BW500 Page 63...
  • Page 64 This function allows the user to simulate an alarm condition: ‘on or ‘off’, which will override normal operation until P119 setting is returned to normal. Values P119 Condition Display (alarm field) normal normal alarm on ALM # alarm off blank Page 64 Accumass BW500 PL-565...

  • Page 65: Ma I/O Parameters (P200 - P220)

    The instantaneous mA values are averaged for the set period, and then the average value is output during the next period while a new average is being calculated. Entry: 0 = off 1 – 999 = averaging period PL-565 Accumass BW500 Page 65...
  • Page 66 P250 mA input range Sets the mA range for the input selected, inputs 1 to 2 (P250 - 01 to – 02). entry: 1 = 0 - 20 mA 2 = 4 - 20 mA Page 66 Accumass BW500 PL-565...
  • Page 67 PID function in the PID freeze auto mode and holds output at last freeze value remote PID setpoint source local PL-565 Accumass BW500 Page 67...
  • Page 68 When performing a remote span, it will first perform a zero, then it will ask you to set up span test. Once loading is withing ±2% of the design test weight, it will perform the span. • For the print command to work, the BW500 must be in Run mode. Page 68 Accumass BW500 PL-565...

  • Page 69: Calibration Parameters (P295 - 360)

    1 = weight 2 = chain Refer to Recalibration on page 41 for execution of the factoring procedure Note: Totalization is halted during the factoring procedure, and resumed only upon return to the run mode. PL-565 Accumass BW500 Page 69...
  • Page 70 (f=12.5) Note: If the ‘legal for trade’ certification switch has been set, the zero limit is ±2%. Enter the maximum allowable % deviation Page 70 Accumass BW500 PL-565...
  • Page 71 The initial span is the reference to which all subsequent span calibrations are compared in determining whether they have deviated beyond an accumulated ±12.5% of the initial span. (f=1) Note: Refer to Initial Span on page 49 for execution. PL-565 Accumass BW500 Page 71...

  • Page 72: Linearization Parameters (P390 - P392)

    Factors out moisture component of load, rate and total for all multispans selected. The factored values are meant to report the dry mean values of the material being conveyed. (f=0.00) Enter the moisture content in % weight. Page 72 Accumass BW500 PL-565...

  • Page 73: Proportional Integral Derivative (Pid) Control Parameters, (P400 - P418)

    Proportional Term Sets the proportional term (P405-01 or -02) for the corresponding PID system (1 or (f=0.400) The proportional term is the proportional gain. A gain of 1 is equivalent to a proportional band of 100%. PL-565 Accumass BW500 Page 73...
  • Page 74 (P402). Entry: 0 = local 1 = mA input 1* 2 = mA input 2* * for PID-01, the setpoint source is mA input 1 for PID-02, the setpoint source is mA input 2 Page 74 Accumass BW500 PL-565...
  • Page 75 Sets the remote setpoint ratio (P418 –01/02) for the corresponding PID system (1 or 2) when P414 = 1 or 2. (f=100) The remote setpoint ratio scales remote setpoint input by the set percentage. A value of 100 means that the setpoint is 100% of the mA input. PL-565 Accumass BW500 Page 75...

  • Page 76: Batch Control (P560 - P568)

    The activity is internally limited to ±10% of the batch setpoint Entry: 0 = off 1 = Auto 2 = Manual Page 76 Accumass BW500 PL-565...
  • Page 77 The setpoint relay will activate when the batch totalizer reaches 950. P598 Span Adjust Percentage Accessible only through manual span adjust (P019), when percent change (1) is selected. Refer to % Change on page 42. PL-565 Accumass BW500 Page 77...

  • Page 78: Totalization (P619 - P648)

    It is used to verify the accuracy of the scale. If a printer is connected to a port and the required programming is in order, a printout of the activity is automatically done on completion of the verification process. Page 78 Accumass BW500 PL-565...
  • Page 79 Selects the totalizer combination to be displayed, either manually through the scroll display key or automatically by control of the display mode (P081). Entry: 1 = totalizer 1 2 = totalizer 2 3 = totalizer 1 and 2 PL-565 Accumass BW500 Page 79...
  • Page 80 Pulses Per Sensor Revolution For speed constant entry (P690 = 2), this parameter is enabled for entry of the pulses per revolution that the speed sensor delivers. Enter the pulses per revolution from the speed sensor nameplate Page 80 Accumass BW500 PL-565...

  • Page 81: Ecal Parameters (P693 - P698)

    Determines the excitation applied to the load cells. (f=10.00) Nominally this value is 10 V. However, a measurement of the voltage at the load cell provides the most accurate entry. Enter the load cell excitation in volts dc. PL-565 Accumass BW500 Page 81...
  • Page 82 Upon entry, display jumps to P017 to display the design load value as the test load. P699 ECal mV Span Applicable only for Milltronics belt scales not listed in P693, or scales other than Milltronics (P693 = 4). Enter the mV span corresponding to 0 to 100% full scale load Upon entry, display jumps to P017 to display the design load value as the test load.
  • Page 83 The offset from Greenwich mean time (GMT) of local time. This parameter does not affect any timed events because all times are local. It can be accessed by a remote computer for synchronization purposes. Enter local time zone –12 to 12 PL-565 Accumass BW500 Page 83...

  • Page 84: Communication (P750 - P792)

    Displays the number or errors. P799 Communications Control Assigns programming control through the local keypad (or Dolphin Plus, P770 = 1), or through a Modbus protocol (P770 = 2 or 3) Entry: 0 = local 1 = modbus Page 84 Accumass BW500 PL-565...

  • Page 85: Test And Diagnostic (P900 - P951)

    Tests the memory. Test is initiated by scrolling to the parameter or repeated by 'pressing enter' Display: PASS = normal FAIL = consult Milltronics. P911 mA Output Test Tests the mA output value for the output selected, outputs 1 to 3 (P911 – 01 to -03) Displays the value from the previous measurement.
  • Page 86 Design Load Displays the value of the design load, which corresponds to the full scale value for alarm and mA output functions. The design load is calculated, based on the design rate and design speed. (f=0.00) Page 86 Accumass BW500 PL-565...
  • Page 87 P999 Master Reset Resets parameters and totalizers to their factory setting. (f=0) Enter ‘9’ to execute the reset PL-565 Accumass BW500 Page 87...
  • Page 88 Page 88 Accumass BW500 PL-565...

  • Page 89: Operation

    If the BW500 is programmed for batch control, the batch display is added to the display scroll. Refer to Batch control From the run mode, access to the program mode, and zero and span calibration is made. PL-565 Accumass BW500 Page 89...

  • Page 90: Damping

    (P220). Note: Damping (P080 or P220) is not applicable to the mA output when programmed for PID function (P201 = 4). Page 90 Accumass BW500 PL-565...

  • Page 91: Ma I/O (0/4-20 Ma)

    For rate, load and speed alarm functions, the high and low alarm setpoints (P101 and P102 respectively) are required and must be entered in the appropriate units. The high alarm setpoint acts as the setpoint deviation alarm for relays programmed for PID setpoint deviation. PL-565 Accumass BW500 Page 91...

  • Page 92: Totalization

    Internal totalizers: • local display (totalizers 1 and 2) • verification totalizer (totalizer 3) • material test totalizer (totalizer 4) • batch total (totalizer 5) External totalizers • totalizer outputs (remote totalizers 1 and 2) Page 92 Accumass BW500 PL-565...
  • Page 93 1 Placing the internal totalizers on to the display scroll of the run mode is controlled by the totalizer display parameter (P647); displaying either one or both totalizers. PL-565 Accumass BW500 Page 93...
  • Page 94 Page 94 Accumass BW500 PL-565...

  • Page 95: Pid Control

    4. setpoint controller – external process variable with or without rate and load control PID loop mA output terminals mA input terminal (mA I/O) (mA I/O) 1 & 2 5 & 6 3 & 4 7 & 8 PL-565 Accumass BW500 Page 95...

  • Page 96: Setpoint Controller - Rate Control

    Setpoint Controller – Load Control motor speed controller belt scale speed sensor load control output (P201-02 = 4) speed optional remote setpoint - load (P255-01 = 1 ) PID 1 process value source -load (P402-01 = 2) Page 96 Accumass BW500 PL-565...

  • Page 97: Setpoint Controller - Master/Slave Control

    (P201-02=4) rate* speed (P201-01 = 1) MASTER PID 1 process value source -load remote setpoint rate (P402-01 = 1) (P255-01 = 1) *P201-03 = 1 also applicable PL-565 Accumass BW500 Page 97...

  • Page 98: Setpoint Controller - Rate And Load Control

    P term can get the process very close to set point, but it would take a very long time. At the very least, an I term is required to eliminate the offset created by the P term. Page 98 Accumass BW500 PL-565...

  • Page 99: Integral Control (Automatic Reset), I

    0.000 to 1.000 • typical operating range: 0.010 to 0.100 • default value: 0.050 The result of the derivative action is that it can make a system more responsive and more stable at the same time. PL-565 Accumass BW500 Page 99...

  • Page 100: Feed Forward Control, F

    4. Adjust the P term accordingly for consistent oscillation and error. Progressively decrease the P term value if there is too much oscillation and error. Likewise, Page 100 Accumass BW500 PL-565...
  • Page 101 6. The I term value can now be set. Begin by entering the default value of 0.2. 7. Restart the feeder (test weights or chains still applied) and feed rate setpoint entered. PL-565 Accumass BW500 Page 101...
  • Page 102 The D term becomes very useful in applications where the material control point is far away from the measuring point. An example of this would be a weigh belt or conveyor with a belt scale Page 102 Accumass BW500 PL-565...

  • Page 103: Programming

    5 and 6 on the mA I/O board. mA input 2 is an external signal normally reserved for controller 2. The signal is input at terminals 7 and 8 on the mA I/O board. PL-565 Accumass BW500 Page 103...
  • Page 104 Input 1: the setpoint is the mA value on input 1, terminals 5 and 6 on the mA I/O board. mA Input 2: the setpoint is the mA value on input 2, terminals 7 and 8 on the mA I/O board. Page 104 Accumass BW500 PL-565...
  • Page 105 - - - - P P P P I I I I D D D D P P P P V V V V 0 0 0 0 2, process variable as the function of the mA input. PL-565 Accumass BW500 Page 105...
  • Page 106 Page 106 Accumass BW500 PL-565...

  • Page 107: Batching

    * Typical relay assignment. Relays 1 – 5 are 24 ♦ available for batch setpoint or pre-warn alarm function. ♦ Typical auxiliary input assignment. Inputs 1 – 5 29 ♦ are available for batch reset. PL-565 Accumass BW500 Page 107...

  • Page 108: Programming

    P566, batch pre-warn set to on (1) or leave off (0) if batch pre-warn selected, access P567, batch pre-warn setpoint enter the pre-warn total access P568, batch pre-act, set to off (0), Auto (1), or Manual (2) Page 108 Accumass BW500 PL-565...

  • Page 109: Operation

    Pre-act Function If repetitive batches are being run, the pre-act function (P568) can be enabled to automatically trip the setpoint relay before or after the batch setpoint is reached in order to assure best batch accuracy. PL-565 Accumass BW500 Page 109...
  • Page 110 Page 110 Accumass BW500 PL-565...

  • Page 111: Certification

    The printout must consist of the following: Start Total: End total of previous print End Total: Accumulated totalizer including Start Total Net Total: End total minus Start Total PL-565 Accumass BW500 Page 111...
  • Page 112 Page 112 Accumass BW500 PL-565...

  • Page 113: Communications

    The BW500 supports two protocols: Dolphin and Modbus. Dolphin is a proprietary Milltronics protocol designed to be used with Dolphin Plus. Modbus is an industry standard protocol used by popular SCADA and HMI systems. PL-565...

  • Page 114: Bw500 And Smartlinx

    • 24 AWG (minimum) • follow proper grounding guidelines for all devices on the bus • use good quality communication grade (shielded twisted pairs) cable that is recommended for RS-232. Page 114 Accumass BW500 PL-565...

  • Page 115: Configuring Communication Ports

    Modbus standard in both ASCII and RTU formats. It also supports direct connection of a printer. The Milltronics protocol is compatible with the Dolphin Plus configuration program. See the Milltronics web site for information on this PC product (http://www.milltronics.com/).

  • Page 116: P771 Protocol Address

    The unique identifier of the BW500 on the network for the selected port, ports 1 to 3 (P771-01 to –03). For devices connected with the Milltronics protocol this parameter is ignored. For devices connected with a serial Modbus protocol this parameter is a number from 1-247.

  • Page 117: P774 Data Bits

    * No modem connected Modem connected P779 modem idle time Sets the time in seconds that the BW500 will keep the modem connected even though no activity is happening. To use this parameter ensure that P778=1. PL-565 Accumass BW500 Page 117...

  • Page 118: P780 Rs-232 Transmission Interval

    All messages and printouts include time and date. Entry: 0 = no message 1 = rate 2 = total* 3 = load 4 = speed 5 = rate, total*, load and speed 6 = rate and total* Page 118 Accumass BW500 PL-565...
  • Page 119 BW500 will be continuously updated. ® Therefore, if you connect a SmartLinx card to the BW500, set P799 = 1 and ® not write anything to the SmarLinx card, your setpoints will be 0. PL-565 Accumass BW500 Page 119...

  • Page 120: Dolphin Protocol

    The protocol is available on all communications ports on all units. This protocol is not available for third party use. The primary use of this protocol is to connect the BW500 to Milltronics’ Dolphin Plus configuration software. Dolphin Plus Screen Shot...

  • Page 121: Modbus Rtu/Ascii Protocol

    At the time of publication of this manual, the Modbus Protocol was located under products / technical publications / communications products / Modbus protocol. Note: Milltronics does not own the Modbus RTU protocol. All information regarding that protocol is subject to change without notice. How Modbus Works As mentioned above, Modbus is a master-slave type protocol.

  • Page 122: Modbus Rtu Vs. Ascii

    Longitudinal Redundancy Check (LRC) for ASCII There is more to the frame than is described above, this is shown to give the user a general idea of what is going on. For a full description, refer to the Modbus specifications. Page 122 Accumass BW500 PL-565...

  • Page 123: Modbus Register Map

    Parameter Values: refer to Parameter Values p.131 identifies the read / write capability for the register being Read: addressed. provides reference documentation for the register being Reference: addressed. PL-565 Accumass BW500 Page 123...
  • Page 124 41,412 32 bits see P408 p. 74 PID 2 Feed Forward Term 41,414 32 bits PID 1 Remote Setpoint Ratio 41,416 32 bits see P418, p. 75 PID 2 Remote Setpoint Ratio 41,418 32 bits Page 124 Accumass BW500 PL-565...

  • Page 125: Modbus Register Map (Cont'd)

    For more information on this data format see page 131 Device Identifier (R40,064) This value identifies the Milltronics device type and is “2” for the BW500. Handshaking Area (Parameter Access) Built into BW500 is an advanced handshaking area that can be used to read and write 32 bit parameters.
  • Page 126 The value sent to the BW500 is 0001001000000000 binary or 4608 decimal. The value “4608” is sent as an integer to register 40,093 to format the output words 40,094 and 40,095 accordingly. Page 126 Accumass BW500 PL-565...
  • Page 127 Process Values (R41,010 – R41,048) Rate, Load, Speed and Total (R41,010 – R41,019) The associated registers provide the readings of rate, load, and speed. Totalizer 1 and Totalizer 2 in engineering units as displayed in the local BW500 display. PL-565 Accumass BW500 Page 127...
  • Page 128 PID 2 Mode Manual Auto PID 2 Freeze PID 2 Setpoint Local Remote Source Zero In progress Span In progress Write Privileges System Configured Not Configured Mode Calibration Mode Run Mode Totaling Not totalizing Totalizing Page 128 Accumass BW500 PL-565...
  • Page 129 * The standard BW500 provides only one mA output (0/4 – 20 mA). The inclusion of an optional mA I/O card provides two mA inputs (0/4 – 20 mA) and two additional mA outputs. PL-565 Accumass BW500 Page 129...
  • Page 130 For BW500 set up for PID control, several registers have been provided for tuning. Refer to PID Control on page 95 and the associated parameters as listed in the register map. Note: Before you can change any of the setpoints, P799 must be set for remote control. Page 130 Accumass BW500 PL-565...
  • Page 131 Modbus drivers. See Format Word for BW-500 on page 125 for details. Text Messages If a Milltronics device parameter returns a text message, that message is converted to a number and provided in the register. The numbers are shown in the table below: Number...
  • Page 132 Number Text Message as displayed on LCD 30008 pass 30009 fail 30010 hold 30011 30012 30013 30014 -32768 value is less than -20,000 32767 value is greater than 20,000 Page 132 Accumass BW500 PL-565...

  • Page 133: Modems

    RS- 232 port on the modem and send special commands. The most popular command set is called the AT, or Hayse, command set. Your modem manual should give details on how to configure it. PL-565 Accumass BW500 Page 133...
  • Page 134 P778, port 1, to the value 1 (Communications through Modem) • set P779, port 1, to the value 300 (Modem Inactivity of 300 seconds) Note: The meaning of these parameters are outlined in the Installation section Page 134 Accumass BW500 PL-565...

  • Page 135: Error Handling

    In the second case, it depends on what the user tries to do. Listed below are various actions and what the expected outcome is. In general, BW500 will not give an error to the user request. PL-565 Accumass BW500 Page 135...
  • Page 136 If the user attempts to write one or more registers that are out of range, an exception response code 2 will be generated. • If using an unsupported function code, undocumented results may occur. The user is encouraged not to do this. Page 136 Accumass BW500 PL-565...

  • Page 137: Troubleshooting

    Specifically Q1: I tried to set a Milltronics device parameter, but the parameter remains unchanged. A1.1: a. Try setting the parameter from the keypad. If it can’t be set using the keypad, check the lock parameter (P000) and, b.

  • Page 138: Error Codes

    Load Cell AD’s are not functioning Consult Milltronics. Err: 227 No process data available. Consult Milltronics. Batch pre-act adjustment > 10% Pre-act adjustment is ignored. Tune process to limit batch error. Integrator not configured...

  • Page 139: Appendices

    Software Updates The software can be updated from a floppy disk by use of a PC (IBM Compatible) with Milltronics Dolphin Plus software. It is recommended that the old software and parameters be saved to your PC before downloading the new software.
  • Page 140 Page 140 Accumass BW500 PL-565...
  • Page 141 Siemens Milltronics Process Instruments Inc. 2000 Subject to change without prior notice Siemens Milltronics Process Instruments Inc. *7ml19981DK01* 1954 Technology Drive, P .O. Box 4225 Peterborough, ON.Canada K9J 7B1 Tel: (705) 745-2431 Fax: (705) 741-0466 www.milltronics.com Printed in Canada...

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